Raised floor panel fabrication method

ABSTRACT

A raised floor panel fabrication method for making raised floor panels of high quality and low cost is disclosed to include the step of using carton steel or stainless steel to make a face panel and a grille having a rectangular open frame formed of four steel bars and intersected ribs welded to the four steel bars of the rectangular open frame, and the step of welding the face panel to the grille.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The present invention relates to the fabrication of raised floor panels for raised flooring and, more particularly, to a raised floor panel fabrication method for making inexpensive raised floor panels of high-strength.

[0003] 2. Description of the Related Art

[0004] Raised floor panels are commonly used for flooring of semiconductor foundries, industrial laboratories, clean rooms, etc. When flooring, raised floor panels are mounted on intersected trusses supported on upright supports above the floor. Conventional raised floor panels for this purpose are commonly made of aluminum alloy by die-casting. FIG. 1 shows an aluminum raised floor panel made according to the prior art. As illustrated, the floor panel 10 a is a rectangular flat member having a face panel 11 a, a frame 12 a at the bottom side of the face panel 11 a, and intersected ribs 13 a in the bottom side of the face panel 11 a within the frame 12 a to reinforce the structural strength of the raised floor panel 10 a.

[0005] Because conventional raised floor panels are commonly made of aluminum alloy by die-casting, they are expensive and less strong. The yield rate of the method of using aluminum alloy to make raised floor panels by die-casting is as low as about 85%. Further, the Torr×Liters/cm2 of aluminum alloy is as high as 4.6×10e−9, not practical for use in a clean room.

[0006] Therefore, it is desirable to provide a raised floor panel fabrication method that eliminates the aforesaid drawbacks.

SUMMARY OF THE INVENTION

[0007] The present invention has been accomplished under the circumstances in view. It is the main object of the present invention to provide a raised floor panel fabrication method, which uses material of low gas releasing property to make high-strength raised floor panels. It is another object of the present invention to provide a raised floor panel fabrication method, which greatly improves the yield rate of the fabrication of raised floor panels. It is still another object of the present invention to provide a raised floor panel fabrication method, which is practical for making inexpensive raised floor panels. The raised floor panel fabrication method includes the step of using strip-like carbon steel or stainless steel materials to make a grille and a face panel where the grille having a rectangular open frame, a plurality of first ribs and a plurality of second ribs fixedly provided within the rectangular open frame and intersected with one another, and the step of putting the face panel on the grille and then welding the face panel to the grille.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008]FIG. 1 is an elevational view of a raised floor panel made according to the prior art.

[0009]FIG. 2 is a raised floor panel fabrication floor chart according to the present invention.

[0010]FIG. 3 is an exploded view of a raised floor panel constructed according to the present invention.

[0011]FIG. 4 is an elevational assembly view of the raised floor panel shown in FIG. 3.

[0012]FIG. 5 is a bottom view of the raised floor panel shown in FIG. 4.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0013] Referring to FIG. 2, a raised floor panel fabrication method in accordance with the present invention includes the steps of:

[0014] (a) using carbon steel (steel of carbon content below 0.08%) or stainless steel (for example, SS400 or SUS304) to make a grille 10 and a face panel 20. (see FIGS. 3-5); and

[0015] (b) putting the face panel 20 on the grille 10 and then fixedly fasten the face panel 20 to the grille 10 by electric welding 20 or resistance welding.

[0016] The aforesaid face panel 20 has a rectangular top face 21, a rectangular bottom face 22, and four peripheral faces 23 peripherally connected between the rectangular top face 21 and the rectangular bottom face 22 in four sides. The bottom face 22 is welded to the top side of the aforesaid grille 10. The aforesaid grille 10 comprises a rectangular open frame 12 formed of four steel bars 11 by welding, a plurality of first strip-like steel ribs 13 provided within the rectangular open frame 12 and welded to two opposite steel bars 11 of the rectangular open frame 12 and arranged in parallel, and a plurality of second strip-like steel ribs 14 provided within the rectangular open frame 12 and welded to the other two opposite steel bars 11 of the rectangular open frame 12 and respectively inserted with the first elongated strip-like steel ribs 13. The second strip-like steel ribs 14 each have a plurality of notches 131, which receive the first strip-like steel ribs 13. Electric welding or resistance welding is employed to weld the first and second strip-like steel ribs 13 and 14 to the steel bars 111 of the rectangular open frame 12.

[0017] A raided floor panel made according to the aforesaid method has the following advantages:

[0018] (a) Low Torr×Liters/cm2: Because steel is used to make raised

[0019] floor panels, the material property of Torr×Liters/cm2 of finished raised floor panels is as low as 1.9×10e−9 much lower than conventional raised floor panels made of aluminum alloy.

[0020] (b) Low manufacturing cost: In comparison with conventional raised floor panels of aluminum alloy, a raised floor panel of steel made according to the present invention is much cheaper (about 30% cheaper).

[0021] (c) High yield rate: In comparison with the yield rate of 85% of the conventional raised floor panel fabrication methods, the invention increases the yield rate up to 95%.

[0022] (d) High structural strength: In comparison with conventional raised floor panels of aluminum alloy of equal size, a raised floor panel of steel made according to the present invention is much stronger.

[0023] (e) Short fabrication time: In comparison with the conventional raised floor panel fabrication methods, the invention greatly shortens the fabrication time.

[0024] While only one embodiment of the present invention has been shown and described, it will be understood that various modifications and changes could be made thereunto without departing from the spirit and scope of the invention. 

What the invention claimed is:
 1. A raised floor panel fabrication method comprising the steps of: (a) using strip-like metal materials to make a grille and a face panel, said grille having a rectangular open frame, a plurality of first ribs and a plurality of second ribs fixedly provided within said rectangular open frame and intersected with one another; and (b) putting said face panel on said grille and then welding said face panel to said grille.
 2. The raised floor panel fabrication method as claimed in claim 1 wherein said strip-like metal materials are made of carbon steel.
 3. The raised floor panel fabrication method as claimed in claim 1 wherein said strip-like metal materials are made of stainless steel.
 4. The raised floor panel fabrication method as claimed in claim 1 wherein said rectangular open frame of said grille is formed of four metal bars welded to one another; said first ribs are welded to two opposite metal bars of said rectangular open frame and arranged in parallel; said second ribs are welded to two opposite metal bars of said rectangular open frame and arranged in parallel and respectively intersected with said first ribs, said second ribs each having a plurality of notches, which receive said first ribs respectively.
 5. The raised floor panel fabrication method as claimed in claim 1 wherein said face panel has a top face, a bottom face welded to said grille, and four peripheral faces peripherally connected between said top face and said bottom face in four sides.
 6. The raised floor panel fabrication method as claimed in claim 1 wherein said face panel is welded to said grille by electric welding.
 7. The raised floor panel fabrication method as claimed in claim 1 wherein said face panel is welded to said grille by resistance welding. 